Method of casting metal.



R. T. HARRIS.

METHOD 0F oAsTme METAL.

APPLICATION FILED JAN. 11, 1910.

Patented Feb. 20, 1912.

3Y SHEETS-SHEET 1.

` 'Rm/st. EI. Inventor.

lnventor. y Ewan E] .Hon/dn.

Attorney.

3 SHEETS-SHEET 2.

Patented Feb. 20, 1912.

lnlrlil R. T. HARRIS. MTHOD 0F GSTINGl METAL.

APPLICATION IILBD IAE. 11, 1910.

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u A Rum, BM inventan:

Patented Feb. 20, 1912.

a SHEETS-SHEET s run srarns PATENT onirica BEESE T. HARRIS, 0F BUFFALO,NEW YORK. v f

METHOD or CASTING METAL.-

Specification of Letters Patent.

To all who/m 'it 'may conca-m: i

Be it known that I, Runsn T.IIARRis, a citizen of the United States,residing at Buffalo, in the county of Erieand State of New York, haveinvented a certain new and use` ful Improved Method of' CastingMetal, ofwhich the following is a specification. This invention relates toimprovements' in the -art of casting metals and Aparticularly to theinethodlof casting steel charging boxes and the like.

The principal objects of the invent-ion are to materially clieapen thecost of casting by siinplifyingthe operation and increasing therapidity, and to produce a casting of even and uniform firmness of metalwhich is not distorted from its regular sha-pe or cracked in cooling andis provided with comparatively smooth surfaces. Y 4

For a full understanding of the nature and character of this improvedmethod of y casting metals, reference is to be had: to the accompanyingdrawings in which a fpreferred adaptation of `a mold capable of ca'r'-25 ry-ing out the'method is shown.

Figure 1 is a transverse section through the mold. Fig. 2 is atransverse section through the mold similar to Fig. 1., biitincludingthemetal casting and illustrating the metal core partially withdrawn fromthe mold. Fig'. 3 is a top plan view of the Yimprovedmold. Fig. 4 is acentral longitudi! nal section through the mold onl line a a,

. form the interior contour of the casting as shown in Fig. 1,'-the'lower inner'edges of its which forms the exterior contour of the metalcasting andis ittedjin the flask@ in the usual y manner. Green sand isthen tamped into 'the flask around the pat-tern" to -securethe imprintof` the pattern and forni the lowerlgreen sand portion 3 -of the mold.'v

Theinterior k c oi'itour of theboxis formed by a metal. elementwhich is.fitted `on the tlask 1 afterthe mold portion ,1 3 'isfcompleted -andthe wooden pat-tern 2 is withdrawn. -This metal element is'preferablyconstructed of two parts or members which are hinged togetherso thatthey can collapse or fold together.v lThe members arepracticallysimilarinisize and shape butv extend oppositelyand areopposed to each other so that when in o pen position the metal elementvwill be of a dished or 'barrel like form.

The members each consist of a lower' ap- Patented Febgeo, 1912.' jApplication iled January V1 1, 1910. Serial 1105531522. l l lyproxii'nately horizontal inwardly extending zportion 4, a verticalmedial portion 5 and a horizontal outwardly extending top iange`'portion 6.

The hinges for connecting the members consist of lugs 7 which extendvup`from the top surfaces ofthe .horizont-al' portions f4 near the innermargins thereof and lap each .v

other, and hingev pintlesjS which are loosel fitted through eye openingsin the lugs.

Two hinges each'consisting of three lugs and a pintle are preferablyutilized, each of -which is located near one end of'v the metal element.i It will be noted that the junction of the lowerhorizontal portion 4and the-medial vertical portion 5 is of a rounded f form. The object ofthis is to 'give a similar round- `ing contour to the interior-fof thecast-ing and also to' enable'the members of the metal element to'beeasily turned on their hinges and withdrawn froml the casting.

When the metal element is infposition to members 'butt closely together,so that an eX- tremely smooth and practically unbroken surface is4presented to the molten nietal'as is 4flows in.

The metal element is collapsed and withdrawn afterthe molten metal-y ispoured in shown tend transversely between membersl and are` connectedat?y their respective ends to the membersby ins 11 which pass throughholes 12 in thebridge bars and holesI 13v in raised cross ribsl onthetopfiange'd'portionsof the members.' 'l Each bridge-bar has a centralvided with an opening 16 in which one of the hooks 9 engage. Each of thebridge bars is additionally connected to one of the members of them'etal element or core by a link 17 which is pivoted atits. inner end bya pin 18 to the bridge bar at a point vertically belowthe opening 16 inthe lug 15, see Fig.1. The outer end of the link is pivoted b y a pin 19to an inwardly projecting lug 20 located near the top of the verticalmedial portion 5,0f one of the members.

The members of the metal element or core are each stiffened andstrengthened on their inner surface by longitudlnal and transverse ribs21 and 22.l

The ends ofthe core are closed by end" pieces which arefformed of sandinserted in place between the endmargins of thevmembers of the metalelement or core when in their separated position, as in Fig. y1.

As theycharging box designed to be 'cast with this improved process andthe mold shown inthe accompanying drawings has a slottedI end and a"plain end, one of theendv pieces is ftnorrned in two separated sections23 and 24 which are fitted together as shown in Fig. `5, andisha'ped toleave the necessary slot This limproved in the slotted end and the otherin one solidv piece 25.

Thepouring hole 26 1s located at one end of the sand portionv of themold land the vent hole 27 at the opposite end of said sand portion.

process is mainlyused in casting thin, narrow elongated pieces of dishedform which are difficult to cast in the ordinary nia-nner with sandcores and practically impossible to cast with solid metal cores.v

In carrying out this process the wooden pattern 2 is first placed ontheflask 1 and green molding sand is thenI rammed into the space between"the flask and pattern to form the lower sand portion 3 of the mold.

The pattern is withdrawn after the sand portion?) is completed and themetal element or core is fitted on the flask and the sand end piecesplaced in the ends of the metal element or core. The molten metal whichforms the casting is now poured in the pouring vhole 26-until it runsout of the vent 27 at thel opposite end. After the casting is poured,the metal element. is collapsed and lifted very quickly from thecastingandv before the.

casting has cooled beyond the surface hardening of the metal.

By removing the metal element the interior surface of' the'jcasting iscompletely exposed to the air so that it may' cool'evenlyl andshrink orcontract freely. This preventsany distortion or cracking-of the metaland produces a casting of regularform and unis form firmness of metal. ly

To prevent sudden chilling of the lmolten metal, the metalelement isheated in any l well known manner before the metal is poured in theflask, for instance, a fire may be built in the metal element.

' The metal element .or core is preferably constructed .of cast iron andit is washed with a composition of graphite and fire clay or any othersuitable composition for producing a smooth non-adhesive surface tocontact with the molten metal. The collapsing'of the metalelement alsobreaks up the sand end pieces of the core, so that the casting whensufficiently cooled can be easily removed from the lower sand portion 3of the mold. But one flask is required with this construction as themetal element serves not only as a core and a cope but also as theentire top portion of the mold.

The wooden pattern 2 is provided on its bottom with two parallellongitudinal ribs 28 which press channels 29 im the surface of the lowersand portion 3 of the mold. These channels lconstitute gates for theflowing molten metal and also 'serve to form corresponding parallellongitudinal ribs 30 on the bottom of the casting. After the4woodenpattern is removed converging grooves or channels 31 are formedwhich extend from the ends of the channels 29 to the pouring hole orgate.

The flask and metal core are pinned to each other sol thatthey willregister properly together. This is accomplished by providing 'flanges32 or the like on the outer mar.- gins of the top portions of thefla-sksides and providing lsuch flanges with vertical pinswhich areadapted to enter openings in the lateral extensions 34 of the metalcore. y End plates 35 are fitted on, the ends of the flask over the endsof the mold and are held in place by weights or clamps. These platesserve to close the top ends of the flask as the core is not as long asthe flask and also pre- 'vent the sand from being forced out over thetop by themolten metal asit is poured in.

One of theprincipal purposes for which this improved method is utilizedis inthe casting of charging boxes from open hearth and Bessemer andother forms ofsteel and directly from the ladle, the'iron beingconverted into' ,'steel and then `carried to and poured ,into the moldwhile still ina molten state.

In carrying out this improved process of casting metal, the lower orsand portion of the moldv is first formed, the metal element, the outervsurface of which has been coated with the non-adhesive composition asbefore described, is fitted in place on the flask, the sand end pieces.are fitted in place, the metal element is heated to about the desiredtemperature, form the casting, 'and the metal element is immediatelycollapsed. and lifted `from contact with the casting.l i l v Theprincipal features of' this improved the molten metal .is poured in to.

method of casting metal reside in simplifying the operation of producingthe necessary mold by dispensing With a sand core and a cope andutilizing in lieu thereof a metal element which forms a permanent coreand cope, in heating the metal element to prevent sudden chilling, inarranging this metal element so thatit. can be immediately Withdrawn assoon as the metal is poured, which exposes the hot casting to the evenand uniform andcOmparatively quick cooling action of the Surroundingair,.and permits itI to shrink and contract freely While cooling topreventl distortion or cracking, in greatly increasing the capacity ofproduction of the molds and castings and in producing perfectundistorted, uncracked and regular castings of even firmness of metal,with smooth surfaces and Without blow holes or defects.

I claim.

l. A method of casting metals which consistsin pouring the molten metalin a mold composed in partof non-friable metal and in part of friablematerial and then When the metal of the casting solidifies `collapsingthe non-friable metal part `of the mold and breaking-up the friablepart'.

2. The *hereinbefore described method of cast-ing metals consisting infirst preparing a mold including a metal element and separate sandelements, heating the metal element to prevent sudden chilling of themolten metal, pouring the molten metal in the mold, and then quicklyremoving the metal elementl of the mold, and simultaneously breaking upsome of the sand elements to completely expose the interior of the hotcasting to the atmosphere.

3. A method of casting metals which consists in pouring the molten metalin a mold composed in part of non-friable metal and in part of riablematerial and then when the metal of the casting solidiliessimultaneously collapsing the non-friable part of the mold and breakingup the friable part.

4. A method of cast-ing metals Which consists .in pouring the moltenmetal in a mold composed in part of non-riable metaland in part offriable material and then when the metal of the casting soliditiescollapsing the non-friable part of the mold and by said collapsingcrushing and breaking up the friable part.

5. A method of casting metals which consists in pouring the moltenmetalin a mold having a composite collapsible core of nonfriable metaland friable material so constructed that the collapsing of the coreportion of non-friable metal will crush and break up the port-ion offriable material and then when the metal of the casting solidifiescollapsing and removing said core.

REEs-E T. Hansis.

lVitnesses:

W. H. EBscoRY, L. M. SANGSTER.

